Food processor

ABSTRACT

A freezer includes a grinder to obtain a ground meat; a mixer to add fat to the ground meat; a payload bay to receive the ground meat; a plurality of evaporators coupled to the payload bay with a multiplicity of coolant tubes in each evaporator, wherein each tube enters and then exits the payload bay, further comprising one or more cryogenic valves coupled to the coolant tubes; a pump to force coolant flowing through the evaporators; and a processor with code for: chopping the ground meat and during chopping, adding salt and ice to the ground meat being chopped and adding liquid nitrogen to maintain the temperature of the meat being chopped below 5° C. to obtain a chopped meat product; adding fat to the chopped meat product and then chopping the fat and adding liquid nitrogen to maintain the temperature of the chopped meat product and fat being chopped between 1° C. and 10° C. to obtain a chopped meat and fat product, wherein the ground meat, added fat, ice and salt are present in amounts so that the chopped meat and fat product has a fat content of from 1% to 20% by weight based upon the weight of the chopped meat and fat product.

FIELD OF INVENTION

The present invention relates to low fat food processing system.

BACKGROUND OF THE INVENTION

U.S. Pat. No. 5,556,662 discloses a process and an apparatus comprisinga cutter for the manufacture of meat batter in which liquid nitrogen isintermittently sprayed onto the rotating blades of the cutter tocounteract the heat produced by operating friction. This process appearsto have a positive influence on the organoleptical properties, theaspect and the keeping properties of the otherwise traditional sausagesmade of this batter. This patent does not suggest that this process andapparatus could be useful for the manufacture of low fat sausages.

Traditional finely comminuted cooked meat sausage products compriseabout 40 to 50% lean meat, 25 to 35% added fat and 20 to 30% water. Asimple approach for the fat reduction is the change of formulation ofsausage products. Instead of added fat, one can use more meat and ice.However, such a reduction of the amount of added fat may lessen thewater binding in the sausage product by way of a strong shrinkage ofprotein matrices during heat treatment due to a poor distribution of fatparticles in these matrices, an increased water content due to thesubstitution of meat and water for fat, and a lower ionic strength inthe aqueous phase.

A known way for recovering a good water binding in such sausage productsis to use fat substitutes or binders such as protein or carbohydratebased substitutes or synthetic compounds. However, fat substitutes arenot always as much appreciated as natural fats and binders can affectthe organoleptical properties of the sausage products.

SUMMARY

In one aspect, a freezer includes a grinder to obtain a ground meat; amixer to add fat to the ground meat; a payload bay to receive the groundmeat; a plurality of evaporators coupled to the payload bay with amultiplicity of coolant tubes in each evaporator, wherein each tubeenters and then exits the payload bay, further comprising one or morecryogenic valves coupled to the coolant tubes; a pump to force coolantflowing through the evaporators; and a processor with code for: choppingthe ground meat and during chopping, adding salt and ice to the groundmeat being chopped and adding liquid nitrogen to maintain thetemperature of the meat being chopped below 5° C. to obtain a choppedmeat product; adding fat to the chopped meat product and then choppingthe fat and adding liquid nitrogen to maintain the temperature of thechopped meat product and fat being chopped between 1° C. and 10° C. toobtain a chopped meat and fat product, wherein the ground meat, addedfat, ice and salt are present in amounts so that the chopped meat andfat product has a fat content of from 1% to 20% by weight based upon theweight of the chopped meat and fat product.

In another aspect, a freezer includes optional shelves in an insulatedpayload bay; a plurality of evaporators coupled to the payload bay witha multiplicity of coolant tubes in each evaporator, wherein each tubeenters and then exits the payload bay, further comprising one or morecryogenic valves coupled to the coolant tubes; a pump to force coolantflowing through the evaporators; sensors coupled to the evaporators ofthe freezer to monitor vital parameters of the freezer; a processor; awireless telemetry system to communicate one or more measuredcharacteristics of the freezer in accordance with a service levelagreement (SLA) to a remote computer; and at least one notificationcomponent that provides a notification associated with a specificcustomer responsive to the measured characteristic of the servicecrossing a pre-defined threshold.

Implementations of the above aspect may include one or more of thefollowing. The service is a temperature service. A maintenanceprediction component can be used to predict when maintenance is needed.At least one notification component sends a message addressed to thespecific customer to notify the specific customer about the measuredcharacteristic crossing the pre-defined threshold. At least onenotification component sends a notification message addressed to aservice to notify the service provider about the measured characteristiccrossing the pre-defined threshold. At least one of a trouble ticket anda billing credit associated with the specific customer is generated inresponse to the notification message. At least one notification devicesends a message addressed to a monitoring entity that is independent ofa service provider providing the service. The characteristic measuredincludes temperature and humidity level, and the pre-defined thresholdis a minimum LNO level necessary for delivery of the temperatureservice. The processor determines ULT performance based on a comparisonof the performance of the each of the plurality of ULT assets incomparison to performance of a reference population of UTL devices. Thedevice is part of a plurality of ULT assets, and wherein measurementsare captured at the plurality of ULT assets by a plurality of sensorsconfigured to communicate the measurements through a routablecommunications network. At least one of the plurality of sensors isconfigured to communicate statistical information based on measurementsof performance or energy consumption of a refrigeration systemassociated with the at least one sensor. At least one of the pluralityof smart sensors is configured to communicate analytical informationbased on a statistical analysis of measurements of performance of theULT device associated with the at least one sensor.

In yet other implementations, the material can be an insulation materialwith one of: a silica micro balloon, polyisocyanurate. The vacuum regioncan be processed by removing residual water vapor and other partialpressure of contaminants. The vacuum region is evacuated to a partialpressure of approximately 0.2 milliTorr. The cryogenic heat exchangercan include one or more tubings and may include redundant tubings. Thecryogenic heat exchanger can be U-shaped tubings covering at least threewalls of the payload bay. The cryogenic heat exchanger can includetubings covering at least four sides of the payload bay. Alternatively,the cryogenic heat exchanger can be one or more coils positioned on thetop and/or the bottom of the vessel. A port can connect to the one ormore tubings to provide input and output connections thereto. A door canallow access to the payload bay, wherein the door comprises three ormore materials having different thermal characteristics.

In another aspect, method to provide ultra low temperature processingand/or storage includes providing insulation and structural supportusing a material disposed in a vacuum region between an external housingand an inner housing; cryogenically processing one or more compartmentscontained in a payload bay; measuring a characteristic of service beingprovided to the specific customer; and generating a notificationassociated with a specific customer responsive to the measuredcharacteristic of the service crossing a pre-defined threshold.

In a further aspect, a method to provide ultra low temperatureprocessing and/or storage includes providing insulation and structuralsupport using a material disposed in a vacuum region between an externalhousing and an inner housing; and cryogenically processing one or morecompartments contained in the payload bay.

Implementations of the above aspect may include one or more of thefollowing. The material can be an insulation material with silica microballoon technology. The process can remove water vapor, partial pressurecontaminates and atmospheric gases from the vacuum region. The processincludes evacuating the vacuum region to approximately 0.2 millitorr.The cryogenic heat exchanger can have one or more heat exchange tubings,and can include redundant tubings. The redundant tubings can be acomplete set of heat exchange tubings operating in parallel with theprimary heat exchange tubings. The redundant tubings can have one ormore tubings branched from the primary heat exchange tubings. Thecryogenic heat exchanger can also include U-shaped tubings covering atleast three walls of the inner housing. The tubings can cover at leastfour sides of the inner housing. A door can be formed with a pluralityof materials each having different thermal characteristics. A changeablerack assembly is supported in the chamber. The system can transmitenergy from the payload bay into the heat exchanger through thechangeable rack assembly. A negative pressure in the payload bay can bemaintained through the use of pneumatic seals on the main door assembly.The cryogenics vacuum pumping via the heat exchanger can provide energyremoval from the payload bay and into the heat exchanger. The surfacesof at least one of the external and inner housing can be flat surfaces.

Advantages of the preferred embodiment may include one or more of thefollowing. The preferred embodiment provides a ULT chamber which is madein compact rectangular form, as opposed to circular or cylindrical form.The preferred embodiment also provides a substantially flat verticaldoor serving as the front panel of the chamber. The system may be usedto monitor, manage, control and report on the operation of equipmentthat may be deployed locally or remotely and/or in large numbers. Tofacilitate description of certain aspects, specific details related torefrigeration and/or freezer assets will be given, and it will beunderstood that the aspects may be practiced without these specificdetails. In one example, methods, apparatus, and computer programproducts are described in relation to refrigeration systems andrefrigeration assets, including ULT refrigerators and freezers,refrigeration plants and cold-storage facilities comprising largenumbers of refrigeration assets. The performance of refrigerationsystems and/or refrigeration assets may be monitored based ontemperature and electrical current and other measurements known,inferred, deemed, and/or correlated with refrigeration performance.Performance may measure and/or characterize the status, heath,reliability and/or energy usage of a refrigeration asset orrefrigeration system. Refrigeration assets in need of repair may beidentified and a repair process may be specified, classified, managedlocally or remotely, and optimized. The immediate effectiveness andlong-term persistence of repairs and energy savings may be determinedover time. The refrigeration assets may be classified, scored, and/orrated according to normalized data, design, reliability, performance,make, model and manufacturer. The effectiveness of repairs may beclassified based on measured performance results following repairs. Theequipment or service providers, including organizations, companies orindividuals providing repair and other services, may be evaluated forthe effectiveness and persistence of repair results using benchmarks andother qualitative or quantitative evaluation methods.

Certain aspects of the present may be described in relation to a varietyof types of refrigeration assets, including refrigeration farmscomprising large numbers of refrigeration assets. Systems and methodsare described that may be used to monitor and analyze performance ofrefrigeration assets, and can identify and select refrigeration assetsin need of repair. In certain embodiments, a repair process may bespecified, scored, classified, managed and optimized. The immediateeffectiveness and long-term persistence of repairs and energy savingsmay be determined over time. The refrigeration assets may be analyzed,evaluated and classified according to type, design, in situ environmentand/or configuration, reliability, energy efficiency, access activity,performance, make, model, manufacturer, performance or the identity ofthe service technician performing the repair, and other logical views.

The effectiveness of repairs and energy savings may be classified basedon the measured results following repairs made by service providers,including organizations, companies and/or individuals providing repairand other services.

Certain systems and methods are provided that can determine the statusand/or state-of-health of a refrigeration asset, determine theeffectiveness and persistence of repairs and energy savings, identifypoorly performing refrigeration assets and manage and control repairprocesses. Systems and methods are provided to monitor refrigerationassets using wired or wireless sensors, which transmit data to anapplication server for analysis and benchmarking of performance. Datamay be processed and measured against time or in reference to predefinedbenchmarks and/or norms in order to determine relative performance inreference to selected peers as defined by query criteria, normalization,or filters. The analysis and results may be represented with a visualindication, mathematical or pattern recognition function, such as a sinewave or a statistical model. The application server may be accessedthrough any web browser or web interface, and the user can have adistinct login identification and password.

The preferred embodiments of the ULT refrigeration system provide longterm processing of biological material at ultra-low temperature, e.g.down to −90 deg.C, with an ultimate target of −150 deg.C. The embodimentprovides temperature accuracy independent of ambient conditions oftemperature and humidity while maintaining uniformity of temperaturethroughout the chamber. The embodiment has an optimal chamber size andshape and requires minimal floor space. Low operating costs are achievedthrough the cryogenic refrigeration method and insulation efficiency. Invarious embodiments, the insulation provides additional reliability inevent of failure of internal tube or external refrigeration source.Components of the system can be easily accessed for maintenance purposeswith minimal side effects. The design allows for ease ofmanufacturability and assembly. The preferred embodiments of the systemcan be flexibly manufactured to different sizes and requirements at alow cost.

In a further aspect, a freezer includes a plurality of shelves in aninsulated payload bay; a plurality of evaporators coupled to the payloadbay with a multiplicity of coolant tubes in each evaporator, whereineach tube enters and then exits the payload bay, further comprising oneor more cryogenic valves coupled to the coolant tubes; a pump to forcecoolant flowing through the evaporators with a pressure of at least 90psi to supply the coolant at each evaporator with at least 20 gallonsper hour of coolant; and a plurality of fans to circulate cooled air inthe payload bay.

In another aspect, a freezer includes

-   -   a liquid Nitrogen inlet capable of convenient attachment to a        customer's liquid Nitrogen supply;    -   a cryogenic flow system that operates at a predetermined        Nitrogen flow;    -   a payload bay with removable shelves;    -   a plurality of evaporators inside the payload bay.    -   A plurality of fans that distribute the cooled air from the        evaporators to the payload bay.    -   a fan and evaporator support structure with a multiplicity of        holes that selectively direct the cooled airflow to provide even        cooling throughout the payload bay.    -   a thermal box immediately outside the evaporators and payload        bay, that effectively thermally seals the payload bay from the        outside environment, significantly reducing heat gain;    -   an electronic controller that maintains a setpoint for the        payload bay, determined by the operator between approximately 20        degree C. and −150 degree C.;    -   a pneumatic latch that secures the freezer;    -   a pneumatic rubber seal that provides an airtight seal for the        payload bay; and    -   electronics and mechanics that controls payload bay temperatures        consistently within +/−3 degree C. of the setpoint throughout        the shipment duration.

In another aspect, a freezer system is designed for freezing acustomer's product at an extremely fast rate compared to prior artproducts, to temperatures as low as −150 C. The freezer is comprised ofa large payload bay, an inlet for the customer's supply of a cryogenicliquid such as Nitrogen, evaporators inside the payload bay, and aplurality of fans adjacent to the evaporators, that deliver extremelycold air to all surfaces of the customer's product for fast convectivecooling. Further, the temperature is controlled at the exhaust port ofthe freezer with a cryogenic solenoid valve.

Advantages of these aspects may include one or more of the following.The preferred embodiment has the capability of reducing the freeze timeof about 100 bags to about 1 hour, which is one-half the time ofconventional freezers. Further, the payload bay has 20 shelves and iscapable of freezing 200 bags in one batch. These almost unheard offreezing times are accomplished by design: 1) The coolant is LiquidNitrogen, having a boiling point of −196 C, almost 100 C colder than therefrigerants used in mechanical freezers; 2) The supply pressure of theLiquid Nitrogen coolant is approximately 100 psi, which is much higherthan conventional Nitrogen freezers, thus significantly increasing thecoolant flow; and 3) The convective cooling properties of the freezerare greatly enhanced through the addition of a plurality of fans insidethe payload bay.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exemplary 3D perspective view of the front of a BlastFreezer.

FIG. 2 is an exemplary top view of the Blast Freezer.

FIG. 3 is an exemplary 3D view of the back inside of the Blast Freezer.

FIG. 4 is an exemplary drawing of the safety valve heating fins.

FIG. 5 is an exemplary cross section top view of the thermal barrier.

FIG. 6 shows an exemplary controller with battery back-up system for theBlast Freezer.

FIGS. 7-8 show exemplary remote management IOT systems for predictivemanagement of one or more freezers.

DESCRIPTION

A detailed description of the preferred embodiment is provided herein.It is to be understood, however, that the present invention may beembodied in various forms. Therefore, specific details disclosed hereinare not to be interpreted as limiting, but rather as a basis for theclaims and as a representative basis for teaching one skilled in the arthow to employ the present invention in virtually any appropriatelydetailed system.

Now referring to FIGS. 1 through 3, the preferred embodiment is afreezer system 1 with a plurality of shelves 7, connected to a coolantsuch as a liquid Nitrogen source, and set to a pressure of 100 psi, forexample. In contrast, conventional liquid Nitrogen freezers aretypically set to 35 psi. The preferred embodiment, with 3 times thepressure, will supply coolant at up to 9 times the flow of conventionalfreezers. The 100 psi pressure will cause flows as high as 30 gallonsper hour of liquid Nitrogen, thus providing extremely fast cooling. Inone embodiment, a pump is used to force coolant flowing through theevaporators with a pressure of at least 90 psi to supply the coolant ateach evaporator with at least 20 gallons per hour of coolant. TheNitrogen source is attached to the freezer 1 with a standard CGA 295fitting 4. The coolant flows to a plurality of evaporators 3 that have amultiplicity of copper tubes 14 in each evaporator, thus maximizing thetransfer of heat from the Liquid Nitrogen to the payload bay 8. Thecopper tube then exits the payload bay, where the cryogenic fluid iscontrolled with a cryogenic solenoid valve 5. The exhaust line is thenattached to a customer portal that provides a pathway for the Nitrogengas to flow outside the building.

As a means of significantly improving the freezing rate, multiple fans 2with typical airflows of 1,000 CFM rapidly distribute air around thecustomer's containers, thus increasing the cooling convection propertiesof the freezer. Also, vent holes 12 and 13 are strategically placed as ameans of ensuring uniform temperature throughout the payload bay.

A separate compartment 10, located between the payload bay and theoutside environment, of between 2 and 4 inches thick contains aplurality of insulation materials that substantially reduces the heatgain of the payload bay from the environment.

A thermocouple, inside the payload bay, measures the temperature at alltimes and sends a signal to the controller 6, where it is carefullymonitored and the temperature is controlled. When the setpoint isreached, the controller 6 will stop the flow of liquid Nitrogen throughthe evaporator coils by turning the cryogenic solenoid valve 5 off. Thecryogenic solenoid valve 5 controls the Nitrogen flow in a location thatis considered unique by those familiar with the state of the art.

Typically, the control valve 5 is located in the coolant path betweenthe source and the freezer 1. Said valve 5 is located at the exhaustport of the freezer, which provides equivalent control, but provides asubstantially warmer environment for the valve, thus increasing thereliability and life of the valve.

The controller 6 monitors the payload bay temperature via a thermocoupleand will use algorithms familiar to those skilled in the art of feedbackcontrol systems, such as PID control, to maintain the setpoint within areasonable limit, such as +/−3 C in the preferred embodiment.

A further advantage of the system is the capability of cooling the roomwhere the freezer is located. All mechanical freezers accomplish coolingby transferring heat from the payload bay to the surroundingenvironment, thus heating the room. Typically, a room with severalmechanical freezers requires a significant air conditioning system tomake the room bearable for employees, and to prolong the life of otherinstruments and equipment in the room. However, in the preferredembodiment, the exhausting Nitrogen is typically of a sufficiently coldtemperature, approximately −100 C, that it is an excellent source forproviding the equivalent of an air conditioner for the room. TheNitrogen gas flows from the solenoid control valve 6, through a heatexchanger similar to an air conditioner evaporator coil, located on thetop of the freezer. A fan forces air through said heat exchanger, wherethe air is cooled and delivered to the room. The fan is controlled bythe freezer electronics, with a thermocouple, also located on top of thefreezer, as the feedback loop. Thus the operator can set the temperatureon the display screen 6 and the room will be cooled to the saidtemperature within reasonable limits.

Another advantage of the Blast Freezer is the capability of heating thepayload bay. Electrical heating pads, such as Silicone rubber heatersare located in the air flow path 9. When the customer sets thecontroller 6 to a temperature that is warmer than the current payloadbay temperature, the heating pads are energized and continue to heatuntil the desired setpoint is reached.

A further advantage of the Blast Freezer is the improvement inefficiency of cooling compared to other Nitrogen freezers.Conventionally, the stainless steel walls 15 of the freezer body anddoor 16 are a conductive thermal path for environmental heat to passthrough the exterior walls and into the payload bay 8. This problem isreferred to as a “thermal short” by those skilled in the art ofthermodynamics. The preferred embodiment, however, decreases theNitrogen usage rate by as much as 30%. To eliminate this heat gain, athermal barrier or disconnect decouples the sheet metal. The thermalbarrier is a gap 17 in the sheet metal approximately ¼ inch wide in thepreferred embodiment, eliminating the metal conductive thermal path. Anon-metal material 18, such as a glass-based epoxy resin laminate,attached to both sides of the gap 17, provides structural support.

Typically, there is also significant heat gain through the gasketbetween the door and the freezer. As a means to reduce said heat gain, arubber pneumatic seal 11 is placed between the door 16 and the payloadbay 8. Said seal is inflated from the Nitrogen gas that is readilyavailable at all times, since it is a by product of the cooling process.A further reduction in heat gain is accomplished with an additionalimpediment to the heat flow by adding a second door 19 interior to themain door 16.

A feature of the Blast Freezer is a means of operating the coolingsystem in event of power loss. Deep cycle batteries provide immediatebackup energy. Further, in the event of prolonged power loss for severaldays, a mechanical valve located in parallel with the solenoid valve 5provides a means for the operator to manually regulate the freezertemperature.

Safety valves 20 are used to prevent excessive pressures in the system.Said valves are generally used in the industry for this type ofapplication. However, a common problem with the safety valve is that theextremely cold temperature of the liquid Nitrogen flowing through thevalve can cause the valve to stick and remain open, when it should haveclosed. Further, this flow causes the valve temperature to plummet,which substantially increases the potential for a runaway condition,keeping the valve open continuously and needlessly, wasting largeamounts of Nitrogen. This failure is known in the industry as “stickyvalve”.

To reduce this problem, heating fins 22 are added to the newly designedsafety valve 21 in the preferred embodiment. These fins 22 keep thetemperature of the valve warmer during pressure relief, thussignificantly reducing the sticky valve problem.

As a further means of improving reliability the preferred embodiment hasno refrigeration compressor, common to most prior art freezers, thusalleviating wear problems associated with the multiplicity of movingparts.

In one embodiment, a Blast Freezer system includes a liquid Nitrogeninlet capable of convenient attachment to a customer's liquid Nitrogensupply and a cryogenic flow system that operates at significantly higherNitrogen flow than conventional freezers. The system includes a payloadbay with removable shelves, a plurality of evaporators inside thepayload bay; and a plurality of fans that distribute the cooled air fromthe evaporators to the payload bay. A fan and an evaporator supportstructure have a multiplicity of holes that selectively direct thecooled airflow to provide even cooling throughout the payload bay. Athermal box is provided immediately outside the evaporators and payloadbay that effectively thermally seals the payload bay from the outsideenvironment, significantly reducing heat gain. The system includes apneumatic latch that secures the freezer and a pneumatic rubber sealthat provides an airtight seal for the payload bay. An electroniccontroller is provided that maintains a set point for the payload bay,determined by the operator between 20 C and −150 C. The electronicscontrol payload bay temperatures consistently within +/−3 C of the setpoint throughout the shipment duration.

In one embodiment, the system can be used to make low fat food such assausage products such as Lyoner, Frankfurter, Wiener, Bologna and Meatloaf, for example. The expression low fat sausage products means sausageproducts having a fat content between 1 and 20%.

The process permits prolonged chopping as compared with traditionalchopping times. The present long and intensive chopping under carefullycontrolled temperature appears to permit the fat particles to be veryuniformly distributed within the meat batter thus preventing a strongshrinking of the meat protein matrices in low fat products duringheating. Scanning electron microscopy showed that the fat particles weresmaller (10-20 μm) and more homogeneous in size in the present productthan in control samples. This prolonged chopping also appears to improveprotein swelling and gelling properties without inducing any proteindenaturation. The extracted soluble protein was about 44% in meatbatters prepared by the present process while it was about 40% incontrols.

The system can use lean meat of pork, beef, mutton or chicken, forexample, namely a meat having a fat content between 1 and 20%, two daysafter slaughtering. One also can use meat of high pH value, namelyhaving a pH>6.0, or so-called dark, firm and dry meat (DFD meat), oreven slaughter warm meat (SW meat).

The added fat is preferably an animal fat, such as backfat which has afat content of about 90%, for example. This added fat may be groundbefore being added to the batter. However, surprisingly good results mayalso be obtained with a vegetable oil such as soya oil, sun flower oilor corn oil, for example.

A batter is prepared which comprises from 40 to 70% meat, up to 20%added fat and from 20 to 50% ice. Especially good results may beachieved with from 50 to 60% lean meat, up to 15% added backfat, andfrom 30 to 40% ice.

Preferably, nitrite curing salt and phosphate are added in respectiveamounts of from 1.2 to 2% and up to 0.3%. Then, 2 to 8 g mixed spices,up to 1 g sodium ascorbate and up to 2 g dextrose may be added per kg ofmeat batter at the time the fat is added. The pH of the batter should bein the range of 5.8 to 6.5. If the pH of the batter is below this range,there is a risk of important deterioration of the water binding in thesausage product. The myofibrillar proteins may namely begin toincreasingly repell water as the pH further drops. An adequateadjustment of pH may even surprisingly permit one not to add anyphosphate to the batter while still having a good water binding in thesausage product. Possible pH adjustments are preferably made by addingsodium carbonate or sodium bicarbonate. Especially good results withrespect to the water binding properties of proteins are obtained byadding up to 3 g of sodium bicarbonate per kg of meat batter. DFD meatcan be used because it has a pH>6.2. SW meat is also especially suitablebecause it permits to have good water binding properties in the sausageproduct. However, this is not only due to the high pH of SW meat butalso to the fact that if SW meat is used for carrying out the presentprocess within a period of about 4 h after slaughtering for beef orabout 1 h after slaughtering for pork, its excellent water bindingproperties will be maintained in spite of ATP breakdown.

Grinding the meat and/or the added fat may be carried out in atraditional meat grinder, for example. Chopping the ground meat and/orfat and further chopping the batter may be carried out in a bowlchopper, of which the cutters may rotate at a speed of 2000 to 6000 rpmwhile the bowl may rotate at a speed of about 10 to 30 rpm, for example.

Stuffing the meat batter may be carried out into natural or syntheticcasings or into cans, for example. Reddening may be carried out byholding for 15 to 45 min at room temperature, for example.

Heating or cooking may be carried out for 15 min to 3 h at 70° to 125°C., either in a cooking chamber, for sausages stuffed in casings, or ina hot water bath or an autoclave for sausages stuffed in cans, forexample. The sausages may then be cooled under cold water and kept in arefrigerated chamber at about 4° to 5° C., for example.

FIG. 6 shows an exemplary Blast Freezer with a controller 100 and abattery back-up unit 110 for the freezer system 1. The controlelectronics includes an interactive Human Machine Interface or HMI 102.The HMI has a touch screen display. Said electronics also includes adata logging unit 104 with real time data, plotted on the display andrecording temperature vs time. The electronics also includes thecapability to transmit data logging information. The payload baytemperature control is provided by a cryogenic valve that is preciselycontrolled by the electronics. Further, said temperature control isachieved through the use of PID or another algorithm known to thoseskilled in the art. Deep cycle batteries in back up unit 110 can provideuninterrupted power in the event of AC power loss. Additional customerproduct thermal safety is provided by an emergency mechanical valve thatregulates freezer temperature. A pneumatic latch and pneumatic rubberseal can be used and can be powered by the pressure derived from theNitrogen exhaust gas. The safety valves have a mechanism to prevent afailure known in the industry as a “sticky valve”, through theattachment of heat exchanger fins to the outside diameter of said safetyvalve. The assembly has a net thermal effect of reducing the temperatureof the surrounding environment, rather than increasing the temperature,which occurs with prior art mechanical freezers. The cryogenictemperature control valve is placed in the exhaust path of the Nitrogengas. Said location provides a warmer temperature location and promoteslonger valve operating life than the standard location that is on thesubstantially colder incoming side of the freezer. The system isemission free and contains no polluting refrigerants such as CFCs orHCFCs. The entire cooling system is highly reliable due to almost nomoving parts. The system has the capability of heating the payload bay.The entire Nitrogen flow is a closed system and the liquid Nitrogen andthe Nitrogen gas never come in direct contact with the customer'sproduct or the employees.

FIG. 7 shows an exemplary schematic diagram 300 illustrating an exampleof a system configured to provide centralized or distributed controland/or monitoring of assets. Wireless transceivers 304, 306 may bedeployed to communicate with, and/or control sensors that monitorcertain aspects of a plurality of corresponding ULT systems. On a largecampus, a sensor network 302 may be configured to more efficientlycollect and distribute sensor data sampled by Wireless transceivers 304,306 from sensors, and/or from other sources associated with ULT assetson the campus. The sensor network 302 may conform to a hierarchicalarchitecture. In one example, a sensor network 302 may have one or morelocal system managers 308 that are deployed to collect and/or aggregatesensor data and other information provided by the Wireless transceivers304, 306. A local system manager 308 may manage and/or comprise anetwork of controllers and/or device managers. The Wireless transceivers304, 306 and the local system manager 308 may communicate through alocal network 310, which may comprise a wired or wireless network.

The sensor network 302 may be coupled to a processing system 320 througha network 312 that may comprise a proprietary wide area network and/or apublic wide area network such as the Internet. The processing system 320may be centralized or distributed over a plurality of networkedcomputing systems. The processing system 320 may provide a plurality offunctional elements and devices, including a data repository 322, whichmay include a database system, an analysis system 324 that may beconfigured to process and analyze measurements, statistical data andtrends, metadata and other information received from the sensor network302. The analysis system 324 may employ historical data, profiles,design goals and other information maintained by the data repository 322to review, process and otherwise analyze information received from thesensor network 302. The processing system 320 may include a repairmanagement system that manages a repair process and service providersinvolved in the repair process using information received or retrievedfrom the sensor network 302, the analysis function 324 and/or the datarepository 322.

In certain embodiments, Wireless transceivers 304, 306 and local systemmanagers 308 of the sensor network 302 may communicate usingconnectionless communications systems. For example, one or more sensorsmay use a messaging service such as a Short Message System (SMS)cellular or a Multimedia Messaging Service (MMS). Other communicationsmethods may be employed, including routable networks. In one example,communication within the sensor network 302 and between the sensornetwork 302 and public or private wide area networks may be based onprotocols that establish a session used to exchange commands and data.In one example, communications may be facilitated through the use ofprotocols that establish a contiguous packet-based data connectionutilizing a single routable protocol or other session comprised ofnon-contiguous data connections used to exchange commands and data.

The data captured by sensors and communicated over a wireless network toa central computer can be used for predictive management as well as formeeting a particular service level agreement (SLA), which is a contractbetween a service provider (either internal or external) and the enduser that defines the level of service expected from the serviceprovider. SLAs are output-based in that their purpose is specifically todefine what the customer will receive. SLAs do not define how theservice itself is provided or delivered. The metrics that define levelsof service for a freezer SLA provider should aim to guarantee:

A description of the service being provided—maintenance of areas such asnetwork connectivity, domain name servers, dynamic host configurationprotocol servers

Reliability—when the service is available (percentage uptime) and thelimits outages can be expected to stay within

Responsiveness—the punctuality of services to be performed in responseto requests and scheduled service dates

Procedure for reporting problems—who can be contacted, how problems willbe reported, procedure for escalation, and what other steps are taken toresolve the problem efficiently

Monitoring and reporting service level—who will monitor performance,what data will be collected and how often as well as how much access thecustomer is given to performance statistics

Consequences for not meeting service obligations—may include credit orreimbursement to customers, or enabling the customer to terminate therelationship.

Escape clauses or constraints—circumstances under which the level ofservice promised does not apply. An example could be an exemption frommeeting uptime requirements in circumstance that floods, fires or otherhazardous situations damage the ISP's equipment.

Though the exact metrics for each SLA vary depending on the serviceprovider, the areas covered are uniform: volume and quality of work(including precision and accuracy), speed, responsiveness, andefficiency. In covering these areas, the document aims to establish amutual understanding of services, areas prioritized, responsibilities,guarantees, and warranties provided by the service provider.

The level of service definitions should be specific and measurable ineach area. This allows the quality of service to be benchmarked and, ifstipulated by the agreement, rewarded or penalized accordingly. An SLAwill commonly use technical definitions that quantify the level ofservice such as mean time between failures (MTBF) or mean time torecovery, response, or resolution (MTTR), which specifies a “target”(average) or “minimum” value for service level performance.

With the sensors, the system's predictive maintenance leverages theInternet of Things (IoT) by continuously analyzing real-time equipmentsensor data via machine monitoring to understand when maintenance willbe required. Technician locations are coupled with replacement/repairequipment available and job completion time to identify the besttechnician available to perform the needed service during a scheduleddowntime. The system leverages real-time condition monitoring andpredictive maintenance to optimally maintain equipment. The systemmaintains the highest equipment availability while decreasing currentcosts:

-   -   Avoid costly corrective or preventative maintenance    -   Ensure performance and availability utilizing real-time sensor        data for condition monitoring and prediction    -   Diminish technician overtime and “just in case” spare parts        inventory levels

FIG. 8 is a block diagram 400 illustrating an example of an architecturefor a Wireless transceiver 402. The Wireless transceiver 402 may beconfigured to connect to a network 230 by any available means. In oneexample, the Wireless transceiver 402 includes a processing circuit 404that may comprise one or more of a microprocessor, a microcontroller, adigital signal processor (DSP), sequencing logic, a state machine, etc.The Wireless transceiver 402 and/or processing circuit may also includea variety of commonly used devices and components such as non-transitorystorage, light emitting diode (LED) lamps or indicators, buttons orswitches and/or an audible alarm indicator. The Wireless transceiver 402may include a communications transceiver 418 that includes radiofrequency, optical or infrared transmitters and/or receivers. TheWireless transceiver 402 may communicate with one or more sensors 422,424, including sensors 422 that are incorporated in or integrated withthe Wireless transceiver 402 and/or external sensors 424 that may becoupled to the Wireless transceiver 402 using wired physical connectorsand/or wireless communications. The Wireless transceiver 402 mayadditionally include a global positioning system receiver (not shown), adisplay controller 430, and user input controllers or drivers 428 thatmay interface with devices such as a keypad, touchscreen or the like.

The processing circuit 404 may include one or more analog-to-digital(A/D) converters 426 configured to receive analog inputs from one ormore of the sensors 422 and/or 424 for example, and one or moredigital-to-analog (D/A) converters 430. The processing circuit 404 mayinclude one or more sensors 422 and/or sensor control circuits. Forexample, certain sensors may be provided in an integrated circuitdevice, on a chip carrier or circuit board that carries the processingcircuit 404. The may be configurable to connect to one or more externalsensor devices 424 The sensors 422, 424 may include transducers that canbe used to sense or measure door position, pressure, acceleration,temperature, humidity, magnetic field, light, load, inclination, radiofrequency identification (RFID) signals and or RFID return signals,whether related to a passive or active RFID tag. The processing circuit404 may include a battery or energy scavenging device and a wired,wireless, infrared, or magnetically coupled interface 418 that iscoupled to an antenna 420 used for communications.

Certain embodiments of the invention employ systems and methods that mayselect assets for repair and that may evaluate the subsequent repairprocess and the results of repairs. In one example, repairs may beevaluated with respect to changes in status, reliability or energyconsumption. An analysis of performance data and metadata may be used toselect assets in need of maintenance and/or repair. In some instances,the analysis of performance data may be used to suggest or select arepair process to address identified performance issues and otherconditions. Information collected during the repair process may becaptured and/or aggregated to assist in later analyses. Such informationmay be used to devise new repair strategies, policies and/or standardoperating procedures.

In certain embodiments, a user may provide contextual information suchas performance characteristics, design, type, make, model, manufacturer,configuration, repair history, configuration settings, environmentalconditions, and other in-service information (which may be collectivelyreferred to as metadata) to facilitate a better understanding of themany factors and variables that could affect performance of ULT systemsand the effectiveness and long-term persistence of repairs and repairmethodologies.

Certain embodiments may employ asset tagging features and methods tocorrelate information obtained from sensors and metadata withperformance analysis and benchmarking information and/or informationidentifying whether repairs result in improved or achievement ofexpected levels of performance. Tags may be added, deleted or changed tocharacterize the state-of-health and status of repairs. In one example,a user and/or the system may increment or decrement the status or stateof a repair to indicate a desired or deemed status of the asset so as tocontrol the next response or action of a service provider. In thismanner, the system can keep the service provider engaged and accountableuntil the repair is determined to have been effective and/or persistentover time, such that the ULT assets performs in accordance with desiredor targeted performance levels and/or for a predetermined period of timeafter the repair.

To facilitate efficient repair and maintenance practices, the repairprocess may be managed and controlled in stages. Stages and gates may bedefined to control progress between stages. For example, certain gatesmay control whether one or more further actions are allowed or notallowed depending on successful completion of previous states, events oroutcomes.

In certain embodiments, systems and methods are provided that reportchanges or improvements, or lack thereof, in measured or observedperformance before, during or after service, maintenance or repairs.Computing devices may be configured to determine if applied maintenanceresults in improved or expected levels of performance. Computing devicesmay be configured to determine whether improvements following repair arepersistent, such that improved or desired performance continues atvarious points and times after time of service.

In certain embodiments, systems can be packaged for wireless transceiverdeployment by a field service technician for example. Sensor generatedinformation and metadata may be processed at deployed systems inreal-time and the results may be stored locally and downloaded forevaluation at a later time, or transmitted periodically through anetwork for evaluation at a central location. In this manner, resultsgathered and processed at wireless transceiver deployed devices may beaggregated, analyzed and/or reviewed centrally using more powerfulanalytical tools and drawing on centralized human and machine expertiseas required. In some instances, information aggregated from disparatesources and/or multiple operators (federated data) may be used by theanalytical tools.

In certain embodiments, information and metadata may be acquiredindirectly and included in processing and decision-making. For example,technicians, operators and other persons performing various operations,including examination, maintenance and/or repair operations related to aULT system may obtain information relevant to the operations and/orstatus of the ULT system, and such persons may enter such informationfor evaluation. In this manner, results and other information gatheredand processed at wireless transceiver deployed devices may beaggregated, analyzed and/or reviewed centrally regardless of whethersuch information is obtained automatically from sensors and otherequipment, or by human intervention or observation. Data that is enteredmanually may include equipment location and historical repairinformation or qualitative or quantitative data related toconfiguration, environmental or operating conditions such as roomtemperature voltage levels measured at one or more points in anelectrical circuit, repair information such as observed condition offilter media, air-flow restrictions, repair type codes and cost ofrepairs for one or more codes. According to certain aspects describedherein, raw data can be imported from another system and included inanalysis.

Certain aspects of the present invention relate to systems, apparatusand methods for identifying and/or selecting ULT assets in need ofrepair and/or managing a repair process for the selected or identifiedULT assets. ULT assets, performance levels of the ULT assets, defects,imperfections and repairs initiated for the ULT assets may be classifiedin accordance with certain aspects disclosed herein. In one example, ULTassets may be classified according to configuration, in situenvironment, reliability, performance, make, model, and manufacturer.The repair process may be optimized and the effectiveness andpersistence of repairs over time may be determined in accordance withcertain aspects disclosed herein. In one example, the effectiveness ofrepairs may be classified in relation to a service provider, which mayinclude a commercial enterprise, internal service organization and/or anindividual selected to perform repairs.

FIG. 6 is a partial state diagram 600 illustrating certain aspectsdisclosed herein. A field service technician may be provided withinstructions identifying or suggesting services and repairs that may beperformed. Notifications may be generated or received indicating whetherthe repairs prove to be effective and persistent over time. In oneexample, notifications may be received from the sensor network 302and/or from service providers responsible for repairs. In an initialstate 602, repairs are considered to be in a pending state. While in thepending state, a service technician may be dispatched. The servicetechnician may be provided with information identifying a ULT system 202to be repaired, one or more symptoms and a repair protocol explicitlyidentifying or suggesting repairs to be made during a service call. Theservice technician may execute the repair protocol or, in someinstances, may replace a failing ULT system 202, and the process movesto a repaired state 604. In the repaired state 604, the target ULTsystem 202 may be tested and/or monitored to determine if the repair waseffective. In one example, testing and monitoring may include ananalysis of sensor data provided by one or more Wireless transceivers218, 226.

If the repair is deemed ineffective, then at state 608, further repairand/or monitoring may be conducted to determine if the effective state606 can be achieved by means of additional repairs or reconfiguration.If the ineffective state 608 cannot be corrected, then the repairprocess may be cancelled and the repair activity enters a closed state614. If the repair has been deemed or determined to be effective, thenin the Effective state 606, the operation and performance of the ULTsystem may be monitored for one or more periods of time to determine ifthe repairs are persistent over time. In one example, monitoring mayinclude an analysis of sensor data provided by one or more Wirelesstransceivers 218, 226. The one or more periods of time may be contiguousperiods of time, or may be spaced over a more prolonged monitoringperiod. In some instances, no further monitoring is needed and therepair process may enter a closed state 614 from the effective state606. The period of time during which repair monitoring is performed atthe Effective state 606 may be identified in a repair protocol and, whenthe effects of the repair persist, the process may move to a Persistentstate 610 from which the process may be manually or automaticallytransitioned to a closed state 614. If, however, the repairs aredetermined to be non-persistent, the process may move to a “NotPersistent” state 612 from which the process may be manually orautomatically transitioned to a closed state 614.

In certain embodiments, system-generated reports can providedocumentation that enable utility companies and municipalities and/orstate entities to provide energy rebates and incentives. The reports maydetermine an amount of incentive or rebate due by calculating deemedenergy savings or net energy savings by adding or subtracting all energygains and losses over a defined time period for each asset, then allmonitored assets in total, thence applying a rate or factor representingthe amount of incentive or rebate due for each unit of energy saved orlost over a prescribed period.

In certain embodiments, a service provider may issue an invoice for arepair, which may include a code issued by the system to confirm that arepair activity meets predefined thresholds and standards forpost-repair performance and effectiveness. The code may be interpretedby a customer of the service provider responsible for repairs asconfirmation that the performance and/or deemed effectiveness or deemedpersistence standards have been met by the repair or that maintenancehas achieved desired levels of performance optimization.

Data Flow in a Repair Process is discussed next. Certain embodiments ofthe invention for measuring the state-of-health of a ULT asset employ orare based on certain systems and methods for monitoring, inferring stateof health, and optimizing efficiency of ULT systems. According to one ormore aspects disclosed herein, ULT systems may be monitored using wiredor wireless sensors (see the Wireless transceiver 402 of FIG. 12, forexample), which transmit data to a processing system 320 (see FIG. 11)for analysis and benchmarking related to performance. Performance datafor a target ULT system may be processed, analyzed, indexed and/orplotted in reference to time, benchmarks and/or predetermined orpredefined norms, in order to determine relative performance of thetarget ULT system in relation to one or more peer systems. The peersystems may be defined based on the classification of the target ULTsystem based on characteristics and attributes such as reliability,configuration, in situ environment, performance, make, model,manufacturer, application and/or an operational history of the targetULT system. The analysis of performance data may employ one or moremathematical or pattern recognition functions, such as a sine wave or astatistical model.

According to certain aspects, contextual information may be obtainedfrom a user or by querying a database or other repository ofinformation. In one example, the user may provide access to contextualinformation such as such as design, make, model, configuration, repairhistory, configuration settings, environmental conditions, and otherin-service information (“Meta Data”) that may facilitate anunderstanding of the various factors and variables that may affect,measure or qualify performance of a ULT system and/or the effectivenessand persistence of a repair process and corresponding repairs.

Certain analytics methods may be applied to discover meaningful patternsand behaviors from the sensor data. A statistical analysis may be usedto examine features as a sample from one or more like sensors to findpopulation norms. Benchmarking may be employed to compare the featuresand/or characteristics of multiple sensors to determine the distributionof values within a population, and to use the corresponding percentileto score the feature of that asset. A time-series analysis may beapplied to identify features for a single sensor over time, and/or todetermine trends or changes, which may indicate the onset of failure.Asset classification may be used to classify or tag assets based oncomputed values, changes over time, etc. Asset classification mayconsider all data to determine if an asset should be tagged for repair,for example. Asset tags can be added or removed based on trends.

Other data may be considered in addition to the sensor data. In oneexample, a fusion of sensor data and disparate data elements may beemployed to learn new things. For example, one or more sensors may beemployed to monitor plug load energy consumption in a defined area suchas in a room. Plug load energy is consequently an object that can bebenchmarked in a manner similar to other objects such as compressorsused in a ULT system. Such sensor data may be fused with other data todetect human activity and energy intensity in the area. In one example,the placement of additional equipment in the room may indicate a new usepattern for the area, or more or less water or lighting being used thanbefore or in comparison to other objects. These new data from externalsources may be mined to derive a better understanding of energyutilization relative to other monitored objects deemed to be similar orcomparable.

One or more maintenance states may be communicated using a gradingsystem that can be expressed graphically and/or textually. For example,a color-coding scheme may be applied to a graphical display indicatingcurrent performance metrics, such as power consumption, cycle variance,temperature curves, and the like. An asset may be graded using aconfigurable and/or familiar color-coding system (Green, Yellow andRed), such that the performance of each asset can be determined incomparison to known achievable levels of performance and energyefficiency to its peers (same make/model) in the population. Gradingscores may be derived from sensor data obtained from sensors associatedwith assets deployed in a variety of settings, locations, andconfigurations.

In one example, assets performing within expectations may be color-codedas Green assets, while underperforming may be coded as Yellow or Redassets. A higher grade (Green) may indicate that the asset is deemed tobe operating efficiently, and/or may be consuming less energy than theaverage of its peers. A next grade (Yellow) may indicate that the scoredasset is exhibiting signs of stress and is consuming more energy thanthe average of its peers. Although there is some potential for energysavings, payback for repairs on these assets may not be as attractive,although repairs and mitigation measures on these assets may achievehigher levels of reliability as an operational policy decision. A lowgrade (Red) indicates serious maintenance, configuration, environmental,and/or other problems. Assets scored “Red” may be immediate candidatesfor repair as they are exhibiting signs of stress consistent withimminent mechanical failure, in addition to wasting significant amountsof energy.

Scoring may be accomplished when enough data for a specific assetmake/model group is available. A color-code score may be assigned toeach asset based on its current performance, before repairs, and/orrelative to its peers in a database of the same or similar make/modelassets. Asset grades may be assigned based on statistical analysis thatmay identify an Optimal Level of Performance (OLP) based on a predefinedstandard deviation. In one example, the top 10% statistically and bestperforming assets for the make/model may be deemed to have achieved theOLP, and no repairs need be performed on these assets and in many casesmaintenance can be deferred for this assets. An asset that is assigned agrade of Yellow may exhibit a calculated annual energy consumption thatis 76% to 89% of the OLP. These assets are candidates for repair. Anasset may be assigned a grade of Red if the projected annualized kWh isless than 75% of the OLP. Such assets may be identified as candidatesfor immediate repair.

In one example, a proxy profile may be used to temporarily assign amake/model profile to an asset. An administrator may select a proxy,which represents a similar asset in terms of size, age and construction.Once it has been determined that the database contains a sufficientlylarge sample for the target make/model, then the proxy or the make/modelgroup may be removed and the system may score the assets using theautomated scoring methodology described above using empirical data.

In another example, estimated asset scoring may be employed when thereis insufficient make/model data in the database to score an asset. Anestimated grade may be assigned based on an analysis of compressorcycling or other known measure of mechanical stress that is highlycorrelated with energy consumption. An asset may be assigned a grade ofGreen if the compressor on-time is below 74%. No repairs need beperformed on these assets. An asset may be assigned a grade of Yellow ifthe compressor on-time is 75%-84%. These assets are candidates forrepair. An asset may be assigned a grade of Red if the compressoron-time is above 85%. These assets may be candidates for immediaterepair.

A benchmark scoring process may be run automatically once per month andprior history is retained by the system such that asset grade changes,attributable to changes in asset performance, can be tracked over timefor each individual asset.

One exemplary repair management process begins when a current (or“pre-repair”) baseline may be obtained from measurements taken for atargeted ULT system, prior to the start of the repair. The currentbaseline and/or one or more other baselines may be created for anyattributes that can be measured or calculated for the ULT system,including in reference to its peers. In some instances, the baseline mayrelate to averages of measurements and calculations obtained from agroup of peer ULT systems or ULT assets. In some instances, the baselinemay relate to measurements and calculations obtained from a specific setof ULT assets classified according to performance within a particularenvironment or context. For example, the performance of a specific setof ULT assets may correspond to hot room, cold room, low airflow, and/orlow voltage configurations.

Next, the system determines that a repair is to be performed for a ULTsystem. The determination may be based on the evaluation of one or morebaselines for one or more attributes of the ULT system. The baselinesmay be used as known achievable goals to guide and/or control the repairprocess. A normal baseline may be identified, where the normal baselineidentifies expected values for a given attribute or operatingcharacteristic of the ULT system to be repaired, or for an idealized oroptimally operating ULT system of a comparable or same type. In oneexample a baseline may be determined from manufacturer-providedinformation. In another example, the baseline may be amanufacturer-provided or user-specified baseline based on experiencewith comparable equipment, or an empirical baseline obtained fromobserved performance of the ULT system targeted for repair, or fromobserved performances of a peer group of ULT systems.

In some instances, recommendations of a make and/or model of ULT assetmay be made for use in a specific context where the recommended ULTasset may not score well in other contexts and/or may exhibit lowerperformance levels when measured on average against its peers. In oneexample, a ULT asset may be recommended when high door access activityis anticipated when the recommended ULT asset exhibits superior recoveryefficiency. In another example, a ULT asset may be recommended for usagein a low-voltage environment. In another example, a ULT asset may berecommended for usage in a room that has poor airflow. In theseexamples, recommendations may be made using alternative scores that aregenerated based on different conditions of installation or use.

Next, the repair is initiated. A repair technician may begin byassessing the equipment health and assigning problem codes and one ormore repair codes associated with the target ULT system. These problemcodes and repair codes may be used to determine expected post-repairperformance levels and/or performance level improvements for the targetULT system, which may be expressed in one or more post-repair baselines.Each of the post-repair baselines may relate or correspond to one ormore measurable or calculable attributes. After the repair is physicallycompleted, the repaired ULT system may be allowed to stabilize prior tocapturing one or more post-repair baselines from measured attributes andperformance parameters of the repaired ULT system.

Next, the one or more post-repair baselines may be used to determine ifthe repair was effective. The determination may be based on one or moreof the measured attributes. In some instances, measurements of all ofthe attributes in the one or more post-repair baselines may not beavailable immediately after repair, and the assessment of theeffectiveness of the repair may be a partial assessment and/orprovisional in nature. One or more algorithms may be applied to compareone or more post-repair baselines with corresponding pre-repairbaselines and/or normal baselines to determine if the repair waseffective. If the repair is deemed not effective at block 1008, then anotation to that effect may be made and a repair may be attempted again.

If the repair is determined to be at least provisionally effective, thenat block 1010 a notation to that effect may be recorded in a log,journal or other information characterizing the repaired ULT system. Aprovisional determination of effectiveness may be confirmed or retractedafter new measurements are obtained after the ULT system has fullystabilized. The expected post-repair baselines may identify the durationof the settling period of time. This decision of effectiveness may bebased on repair codes and on the peer group that is being used forcomparison.

In the event that an effective repair is determined, the repaired ULTsystem may be monitored for a period of time after the repair is deemedeffective to determine whether the repair is persistent. In someinstances, the latter determination may be used to determine if autility incentive payment may be applicable. For example, the period oftime may be selected based on a deemed measure defined by an energyprovider who offers energy incentives and rebates for energy efficiencymeasures. A persistent repair may be a repair that returns the repairedULT system to normal operation for a prolonged period of time. Normaloperation may be defined by the system, an operator, an energy producer,or the like. The prolonged period of time may be determined when therepair is initiated. Various criteria may be applied to define the pointat which the repair may be determined to be persistent over time. Insome embodiments, a counter, timer and/or other metering device may beemployed to measure elapsed time from repair until the point at whichthe repair can be determined to be persistent. In one example, a timermay be initiated to define a time-based monitoring period during whichtotal energy consumption must remain below a predetermined threshold. Inanother example, a cycle counter may be configured to define a range ortotal number of cycles or amount of compressor active/on-time to beachieved or maintained in order to determine persistence of repair.

The timer, counter and/or other meter may be monitored to determine whenthe repair can be deemed effective. If the monitoring period has notexpired, the performance of the repaired ULT system may be continuallyor continuously assessed during the monitoring period and post-repairbaselines may be updated or augmented with measurements obtained duringthe monitoring period. Accordingly, additional determinations ofeffectiveness of the repair may be made during the monitoring period. Inone example, the additional determinations of effectiveness may continueuntil the repair is determined either ineffective or effective andpersistent, after expiration of the monitoring period. Problem andrepair codes may be analyzed, correlated and associated with thespecific make/model or design of the ULT system to programmaticallyascribe, for future reference, recurring problems and repair codes forspecific make/models or designs.

In some instances, measurements captured at a plurality of ULT assets byone or more smart sensors, Wireless transceivers, or smart modules maybe configured to communicate the measurements through a datalogger. Thedata logger may be implemented using circuits or modules of the smartsensors, Wireless transceivers, or smart modules. The datalogger maystore or otherwise maintain sensor data and other information that canbe communicated through a network after the datalogger has identified orestablished a network connection. In certain examples, informationcollected from smart sensors, Wireless transceivers, or smart modulesmay be transmitted to an analysis system through a network at apredefined rate (e.g. every 4 or 8 minutes) as a bundle of observationsmade a faster rate (e.g., every 30 second or every minute), and/or atthe earlier of a longer-term timer (1 hour) or alarm. In some examples,the datalogger, smart sensors, Wireless transceivers, or smart modulesmay be adapted to execute one or more data processing algorithms usingthe sensor data. In some examples, the datalogger, smart sensors,Wireless transceivers, or smart modules may be adapted to manage certainaspects of a repair process, including enabling a wireless transceiversupervisor to oversee the work of less qualified service personnel.

According to certain aspects, multiple evaluation periods may be definedin order to determine whether a repair is persistent. These evaluationperiods may be contiguous and the performance of a repaired ULT assetmay be evaluated independently during each evaluation period. In someinstances, one or more evaluation periods may overlap. For example,first and second evaluation periods may both commence immediately afterrepair of the ULT asset. The second evaluation period may span a longerinterval of time than the first evaluation period.

Configurable parameters may be used to determine the duration of themonitoring period used to evaluate the persistence of a repair.Persistence may be measured over time and one or more parameters maydynamically adjust the persistent threshold to account for normalmechanical degradation and/or changes in configuration or environment.In some instances, one or more additional “persistence” baselines may beestablished for one or more attributes. The persistence baseline may becompared with the post-repair, pre-repair and/or normal baselines todetermine if the repair persisted over the specified monitoring period.If the repair persisted, the repair process may be deemed complete. Ifthe repair is not effective or does not persist, a decision to attemptanother repair of the ULT may be made. The decision may rest upondifferences observed in the various baselines related to previousrepairs, improvements or degradations in performance and any newinformation obtained during previous repairs to the same, similar orcomparable systems. Persistence of a repair may be based on a comparisonmechanical or energy performance to a set point, benchmark, rule, methodor standard.

Certain calculations using the baselines derived from or established forpeer groups and the post-repair baselines may enable the system to flagthe repairs as either effective or persistent based on the time frameduring which the calculations are performed. The peer group mayestablish and/or define acceptable values for various attributes to bemonitored. The peer group may account for in-situ variables to enablethe evaluations to calibrate for the actual ULT system that is beingrepaired. The in-situ variables may include operational parameters suchas set point, airflow, supplied power, power quality levels, and ambienttemperature. Leveraging pre-repair snapshots may enable an accurateevaluation of the effectiveness and persistence of repairs.

In some instances, a ULT system may be selected for repair based on ananalysis of performance data and/or in comparison to Meta Data. MetaData may include repair codes and repair costs, for example. Theselection process, pre-repair, post-repair, persistence and otherbaselines may be used to modify repair processes and/or to devise newrepair strategies, improved repair strategies, policies or standardoperating procedures.

Asset tagging features and methods may be employed to facilitatemanagement of the repair process. Asset tagging features may be used tocorrelate sensor measurements, Meta Data and measured, estimated orcalculated performance of ULT systems. Asset tags may be added, deletedand/or changed in a manner that characterizes the state-of-health of aULT system and status of repairs associated with the ULT system. In oneexample, asset tagging may include a status indicator that can beincremented, decremented, or otherwise modified to indicate progress,status, state of a repair and/or or changes in performance. The assettag may be used to control a service provider's next action or response.In this manner, the service provider may remain engaged and accountableuntil the repair is deemed effective and/or persistent, as determined bydesired or targeted levels.

To facilitate efficient repair and maintenance practices, the repairprocess may be managed and controlled in stages, with gates that allowor disallow further actions. The gates may be operated based onsuccessful completion of previous states, events or outcomes. Progressmay be measured based on the current stage of the repair process. In oneexample, payment of a service provider invoice may be conditioned on theinclusion in the Invoice of a system-issued code indicating theeffectiveness or persistence of the repair

In some instances, changes or improvements in performance of a ULTsystem, or lack thereof, may be reported before, during or afterservice, maintenance or repairs. Effectiveness of a repair ormaintenance may be automatically determined based on whether improved orexpected levels of performance are measured after the repair and/ormaintenance. Information identifying the status, effectiveness and/orpersistence of repairs and/or maintenance may be provided on a dynamicdisplay of system status. For example, performance of a population ofULT systems may be tagged with a qualitative color code, highlights orother means to identify failing, underperforming, and repaired ULTsystems. The status of ongoing repairs may be highlighted until therepair is deemed persistent. Historical information, including statusperformance levels and repair codes may be provided in an alert, alarmand/or scheduled or ad-hoc report.

Various aspects disclosed herein may be implemented in a distributedcomputing system. In one example, a field service technician may beequipped with a portable computing system that can communicate with alocal or wireless transceiver application server. The portable computingsystem may maintain copies of information related to systems to berepaired. In one example, the portable computing system may maintain orhave access to various baselines associated with an underperforming ordefective ULT system. The portable computing system may maintaininformation including sensor measurements and Meta Data that can beprocessed in real-time. The results of such processing may be providedto a networked resource that is configured or adapted to performdetailed analysis of the information and provided profiles and baselinesto be evaluated by more skilled individuals or decision support systems.The portable computing system may provide the repair technician withreal-time results of the repair and feedback from network resources. Theportable computing system may provide a field service technician withinstructions regarding services and repairs to be performed. In someinstances, the portable computing system may notify the field servicetechnician when repairs are deemed effective and/or persistent. In someinstances, the portable computing system may provide instructions orsuggestions from another skilled or specially trained person or manager.

In some embodiments, information may be generated that document energyefficiency and savings. Such information may be used to determineappropriate or contracted utility energy rebates and incentives. Forexample, reports may be generated that determine the amount of incentiveor rebate due by calculating energy savings or net energy savings byadding, and/or by subtracting all energy gains and losses over a definedtime period for each asset. The calculations related to an incentive orrebate may be based on rules and methods set by an energy provider. Atotal energy savings or efficiency for all monitored assets may then beused to calculate rebates and incentives by applying a rate or factorrepresenting the amount of incentive or rebate due for each unit ofenergy saved or lost over a prescribed period. In some instances, energysavings may be projected over a long period of time to determine theincentive payment due from a utility for the specified period of time,based on projected performance which may include adjustments to accountfrom normal mechanical degradation and other factors likely to occurduring such period.

In some instances, the status information regarding a repair ormaintenance event may be used to generate and invoices. In one example,an invoice issued by a service provider may include a system-generatedcode that confirms the performance levels of a repaired ULT system,effectiveness and/or persistence of a repair. The code may beinterpreted by a customer as confirmation that the repair or maintenancehas achieved a desired level or result. The desired level or result maybe based on the achievement and/or persistence of improved levels ofhealth, reliability, and energy efficiency or that it may have done sofor a period of time.

In another method for managing and controlling a network of ULT system,measurements captured at a plurality of ULT systems are received. Themeasurements may include measurements of temperatures and energyconsumption and compressor performance that characterize the performanceof each of the plurality of ULT systems. The measurements may becaptured at the plurality of ULT systems by a plurality of smart sensorsconfigured to communicate the measurements through a network, or may bemanually entered or programmatically uploaded into the system by othermeans. At least one of the plurality of smart sensors may be configuredto communicate statistical information based on measurements ofperformance of a ULT system associated with the at least one smartsensor. At least one of the plurality of smart sensors may be configuredto communicate analytical information based on a statistical analysis ofmeasurements of performance of a ULT system associated with the at leastone smart sensor.

Next at least one ULT system that is performing below an optimal levelmay be identified or determined. The optimal level is determined basedon a comparison of the performance of a reference population of ULTsystems identified in a history of prior measurements. Next, a repairprocess for the at least one ULT system may be initiated. At least oneULT system may be monitored for a predefined period of time to determinewhether the at least one ULT system is performing at the optimal levelor above for a predefined period of time after the at least one ULTsystem has been repaired.

Although the invention has been described in detail in the foregoing forthe purpose of illustration, it is to be understood that such detail issolely for that purpose and that variations can be made therein by thoseskilled in the art without departing from the spirit and scope of theinvention except as it may be limited by the claims.

What is claimed is:
 1. A food processing machine, comprising: a grinderto obtain a ground meat; a mixer to add fat to the ground meat; apayload bay to receive the ground meat; a plurality of evaporatorscoupled to the payload bay; a pump to force coolant flowing through theevaporators; a processor with code for adding fat to the chopped meatproduct and then chopping the fat and adding liquid nitrogen to maintainthe temperature of the chopped meat product and fat being choppedbetween 1° C. and 10° C. to obtain a chopped meat and fat product.
 2. Amachine according to claim 1 wherein the lean meat has a fat content ofbetween 1% and 20%, comprising chopping the ground meat and duringchopping, adding salt and ice to the ground meat being chopped andadding liquid nitrogen to maintain the temperature of the meat beingchopped below 5° C. to obtain a chopped meat product.
 3. A machineaccording to claim 1 wherein the process is carried out without additionof a substance for binding water in a sausage product.
 4. A machineaccording to claim 1 wherein during the chopping of the chopped meatproduct, the processor maintains temperature below 10° C.
 5. A machineaccording to claim 1 wherein the meat has a pH6.0.
 6. A machineaccording to claim 1 wherein the meat is DFD meat.
 7. A machineaccording to claim 1 wherein the meat is slaughter-warm meat.
 8. Amachine according to claim 1 further comprising adjusting the pH of thebatter product to a pH of from 5.8 to 6.5.
 9. A machine according toclaim 8 wherein the pH is adjusted with sodium bicarbonate.
 10. Amachine according to claim 1 wherein the mixer adds phosphate duringchopping of the ground meat.
 11. A machine according to claim 10 whereinthe phosphate is sodium diphosphate.
 12. A machine according to claim 1wherein, by weight based upon a weight of the batter product, the groundmeat which is chopped is in an amount of from 40% to 70% and the ice isadded in an amount of from 20% to 50%.
 13. A machine according to claim1 wherein, by weight based upon the weight of the batter product, theground meat which is chopped is in an amount of from 50% to 60% and theice is added in an amount of from 30% to 40% and wherein the fatcomprises backfat.
 14. A machine according to claim 1 further comprisingadding up to 2 g dextrose per kg ground meat during further chopping ofthe chopped meat product.
 15. A machine according to claim 1 wherein thefat is a ground animal fat.
 16. A machine according to claim 1 whereinthe fat is a vegetable oil.
 17. A machine according to claim 16 whereinthe vegetable oil is selected from the group consisting of soya oil,sunflower oil and corn oil.
 18. A machine according to claim 1 whereinthe stuffed batter product is reddened at room temperature for 15minutes to 45 minutes and the reddened product is heated for from 15minutes to 3 hours.
 19. A machine, comprising: a liquid Nitrogen inletcapable of convenient attachment to a customer's liquid Nitrogen supply;a cryogenic flow system that operates at a predetermined Nitrogen flow;a grinder to obtain a ground meat; a mixer to add fat to the groundmeat; a payload bay to receive the ground meat; a plurality ofevaporators inside the payload bay. a plurality of fans that distributethe cooled air from the evaporators to the payload bay; and aninteractive Human Machine Interface (HMI) to with code for: i. choppingthe ground meat and during chopping, adding salt and ice to the groundmeat being chopped and adding liquid nitrogen to maintain thetemperature of the meat being chopped below 5° C. to obtain a choppedmeat product, ii. adding fat to the chopped meat product and thenchopping the fat and adding liquid nitrogen to maintain the temperatureof the chopped meat product and fat being chopped between 1° C. and 10°C. to obtain a chopped meat and fat product, iii. wherein the groundmeat, added fat, ice and salt are present in amounts so that the choppedmeat and fat product has a fat content of from 1% to 20% by weight basedupon the weight of the chopped meat and fat product.
 20. The machine ofclaim 19, comprising a fat sensor coupled to the processor that measuresa fat characteristic of the meat.